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Abstract Mining shovel is a crucial piece of equipment for high-efficiency production in open-pit mining and stands as one of the largest energy consumption sources in mining. However, substantial energy waste occurs during the descent of the hoisting system or the deceleration of the slewing platform. To reduce the energy loss, an innovative hydraulic-electric hybrid drive system is proposed, in which a hydraulic pump/motor connected with an accumulator is added to assist the electric motor to drive the hoisting system or slewing platform, recycling kinetic and potential energy. The utilization of the kinetic and potential energy reduces the energy loss and installed power of the mining shovel. Meanwhile, the reliability of the mining shovel pure electric drive system also can be increased. In this paper, the hydraulic-electric hybrid driving principle is introduced, a small-scale testbed is set up to verify the feasibility of the system, and a co-simulation model of the proposed system is established to clarify the system operation and energy characteristics. The test and simulation results show that, by adopting the proposed system, compared with the traditional purely electric driving system, the peak power and energy consumption of the hoisting electric motor are reduced by 36.7% and 29.7%, respectively. Similarly, the slewing electric motor experiences a significant decrease in peak power by 86.9% and a reduction in energy consumption by 59.4%. The proposed system expands the application area of the hydraulic electric hybrid drive system and provides a reference for its application in oversized and super heavy equipment.

Mining shovel is a crucial piece of equipment for high-efficiency production in open-pit mining and stands as one of the largest energy consumption sources in mining. However, substantial energy waste occurs during the descent of the hoisting system or the deceleration of the slewing platform. To reduce the energy loss, an innovative hydraulic-electric hybrid drive system is proposed, in which a hydraulic pump/motor connected with an accumulator is added to assist the electric motor to drive the hoisting system or slewing platform, recycling kinetic and potential energy. The utilization of the kinetic and potential energy reduces the energy loss and installed power of the mining shovel. Meanwhile, the reliability of the mining shovel pure electric drive system also can be increased. In this paper, the hydraulic-electric hybrid driving principle is introduced, a small-scale testbed is set up to verify the feasibility of the system, and a co-simulation model of the proposed system is established to clarify the system operation and energy characteristics. The test and simulation results show that, by adopting the proposed system, compared with the traditional purely electric driving system, the peak power and energy consumption of the hoisting electric motor are reduced by 36.7% and 29.7%, respectively. Similarly, the slewing electric motor experiences a significant decrease in peak power by 86.9% and a reduction in energy consumption by 59.4%. The proposed system expands the application area of the hydraulic electric hybrid drive system and provides a reference for its application in oversized and super heavy equipment. [ABSTRACT FROM AUTHOR]

Valve-controlled electro-hydraulic technology is widely used in heavy-duty linear actuator, but its energy efficiency is low. The electro-mechanical actuator (EMA) has high energy efficiency, but its output force is small. In order to achieve high efficiency, high power-to-weight ratio, and high performance linear drive, a hydraulic–electric hybrid linear drive principle integrating hydraulic cylinder and EMA is proposed, and a prototype of electromechanical hydraulic hybrid actuator (EMHA) is designed and developed. In the hybrid drive system, EMA is responsible for actuator motion control and hydraulic cylinder is used for force control. In the study, an extended state observer (ESO) was first designed to estimate the external load torque of the EMA permanent magnet synchronous motor (PMSM) in real time. Combining the detected pressures, the load force of the EMHA can be estimated. Then, according to the estimated load force, the hydraulic system is controlled to make the hydraulic cylinder balance most of the actuator load force, maintaining the PMSM within the required load range. A sliding-mode controller is further designed to compensate the external load torque acting on the PMSM to ensure that the system has good motion control characteristics. The results show that under the same driving force and velocity, the power density of the EMHA is 154% higher than that of the EMA. In this article, the proposed system can achieve equivalent control performance as the valve-controlled system, while reducing energy consumption by 58%. [ABSTRACT FROM AUTHOR]